Valance corner

ABSTRACT

A valance corner including an engagement portion having first, second and third mating surfaces and a sealing edge, wherein the sealing edge includes first and second sealing extensions arranged orthogonal relative to each other and having first and second ends, respectively, each of the first, second and third mating surfaces are arranged orthogonal relative to the other mating surfaces and the first and second mating surfaces form the first and second ends of the sealing edge, respectively. The valance corner further includes a securing portion having first and second securing extensions arranged orthogonal relative to each other, the securing portion fixedly secured to the engagement portion. The first and second securing extensions are arranged parallel to the first and second sealing extensions, respectively.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims the benefit under 35 U.S.C. §119(e) ofU.S. Provisional Patent Application No. 61/365,599, filed Jul. 19, 2010,which application is incorporated herein by reference.

FIELD OF THE INVENTION

The invention broadly relates to protective cases, more specifically tovalances for protective cases, and even more particularly to valancecorners for protective cases.

BACKGROUND OF THE INVENTION

Protective custom fabricated cases and/or containers are used totransport equipment from one location to another, e.g., case 10.Equipment is transported and stored in the case, and subsequentlyremoved from the case for use. Such cases are known by several names,e.g., road cases, flight cases, hard-shell cases, ATA cases (AirTransport Association specification 300 Cat 1: Specification forPackaging of Airline Supplies), musical instrument cases and reusableshipping containers. These types of cases are used for goods andequipment that are transported many times, for example to concerts,stages, trade show, sporting events.

These cases are typically constructed having two or more sections, andinclude a minimum of lid shell 12 and base shell 14 to contain thecase's contents. Trade-offs between case mass and structural integrityare often made based on the price point of the case. A preferredprotective case is lightweight to minimize shipping cost andstructurally sound to protect the contents contained therein.

The exterior portions of protective cases are generally formed by twotypes of construction, molded resin or fabricated panels. It should beappreciated that case 10 shown in FIGS. 1 a-1 c is a fabricated panelcase. In either type of construction, inherent structural weakness areasexist at the joints 16 and/or joining faces 18. Furthermore, any type ofprotective case has one or more peripheral rims 20 and 22 where the lidand base shells matingly engage. It is well known in the art to use avalance or channel to strengthen these peripheral rims.

These valances, e.g., valances 24 a, 24 b, 26, 28 and 30, are formed asintegral parts of the structure of a protective case. Such valances aregenerally manufactured from aluminum extrusions or plastic extrusions astwo distinct and separate components. The two components include a malecomponent and a female component, e.g., male component 32 and femalecomponent 34. The male component has tongue protrusion 36, while thefemale component has recessed groove 38. The male and female componentprofiles unite to form a set. When coupled together, they formed ageneral H-shaped member in a cross-sectional view, as shown in the leftportion of FIGS. 2 a-1 and 2 a-2. In view of the foregoing, it should beappreciated that when a case is closed, the tongue portion is held inplace by the groove portion. The valance provides resistance fromlateral impacts to the lid and base shells thereby preventing lateralshifting between the shells. Additionally, the tongue and grooveprofiles minimize moisture and dust from entering the case.

The peripheral rim of each shell is inserted into the space between thevertical portions of the H-shaped member of the valance extrusions,i.e., spaces 40 a and 40 b, and is then secured to the extrusions byvarious means such as mechanical fasteners, adhesives, etc., e.g.,rivets 42. As a matter of convention, the female component is typicallyattached to the lid of the protective case and the male component isattached to the base.

Molded cases only require a valance extrusion that is joined to theperipheral rim of the top and bottom portions of the case. Generally,molded cases have large radius edges at the corners of the peripheralrim. The valance extrusions are bent around tooling jigs to match theradius of the case corners and attached to the peripheral rim, e.g.,valance extrusions 30. Molded cases are restricted to the size oftooling used and cannot be adjusted to the size of the equipment inside.Thus, many molds are needed to accommodate the wide variety of equipmentstored inside, which molds are often expensive to fabricate.

Fabricated cases can be more readily sized to match the contents thecase is intended to contain, while only using a minimum amount ofmaterial. Most fabricated cases are rectilinear, forming a box shape.Fabricated cases require more labor and skill to produce than moldedcases but do not require the high cost of tooling to form the shapesneeded for a molded case.

Fabricated cases are made by joining panels, e.g., panels 44 a, 44 b, 44c, 44 d and a bottom panel (not shown) together and reinforcing theedges and joints with ninety degree angle shaped extrusions along theexterior edges and valance extrusions to strengthen the case. Theinherent problems with a fabricated case are joining the various panelstogether to produce a robust enclosure, while minimizing the weight byusing the least amount of structure.

Generally the panels are made from laminated sheets, e.g., a plywoodsubstrate with a protective plastic sheet or various composite materialsbonded together. As these types of cases are often rectilinear in space,the joints in such fabricated cases are perpendicular to each other.After the valance is installed on the peripheral rim of a shell, aright-angle brace or clamp, e.g., brace 46, usually made of metal, issecured over top of the valance at each corner of the peripheral rimwith mechanical fasteners, e.g., rivets 42. The brace strengthens theperipheral rim and prevents the valance from separating while coveringthe sharp ninety degree edge and seams.

To make the valance fit the case, linear lengths of extrusion aremitered at each corner of the case, e.g., extrusions, 48 a, 48 b, 48 c,48 d, 48 e and 48 f. A length of extrusion is cut for each panel aroundthe peripheral rim. Miter cuts 50 at each end of the valance extrusionmust be made one at a time typically at a forty-five degree angle. On astandard box style case, sixteen miter cuts are required to make avalance. Such miter cutting is a time consuming process.

Some case builders have developed or use special tools to speed thisprocess. A vertical cutting saw with two blades cuts a perpendicularV-shaped notch in the extrusion. This cut removes material behind theexterior wall of the extrusion, while leaving the exterior wall intact.The valance extrusion is then folded at these cuts to create the shapeof the peripheral rim of the case, i.e., the valance forms a ninetydegree angle between the portions of the valance on opposite sides ofthe cut. This is shown in valance extrusions 28 at corner 52. Thisspecialized vertical cutting saw is a large expense compared toconventional cutting equipment that many fabricators can noteconomically purchase or justify. Even with the specialized verticalcutting saw, miter cuts in the valance are made one at a time, or inother words, are excessively time consuming.

Some manufacturers have developed systems of unique corners and linearmembers to try and solve this problem. These products requirespecialized extrusions and machinery to be utilized. For example, aGerman company, Adam Hall, has a case system called Easycase. It is acomponent system of plastic corners and specialized aluminum extrusionsused to fabricate a case. The corners include projections that insertinto a special cavity in each extrusion. Both the corners and extrusionswork together but can not be used with conventional case building parts,and thus cases manufactured using this system are more expensive thancases formed from more standard components. During fabrication, specialmachinery is needed to permanently attach the corners to the extrusions.Moreover, these plastic corner systems do not meet ATA 300 Cat 1specifications for flight shipping, and therefore have limitedapplication.

As can be derived from the variety of devices and methods directed atforming valances for a protective case, many means have beencontemplated to accomplish the desired end, i.e., cost effective andeasy to fabricate valance corners. Heretofore, tradeoffs between costand performance were required. Thus, there is a long-felt need for avalance corner that is easy to manufacture which incorporates standardprotective case components.

BRIEF SUMMARY OF THE INVENTION

It has been found that it is advantageous to provide an invention thatis a valance corner with an integral tongue and groove that eliminatesthe need for specialized machinery and accuracy in fabricating a miteredcorner while using currently available components and tools.

The present invention valance corner increases the speed with whichfabricated cases can be built, is designed to work with currentlyavailable extrusion valances, and does not require any additional toolsor equipment for a case builder. The present invention valance cornerfurther provides the strength and rigidity needed to support the ninetydegree corner of a case.

The present invention valance corner saves a case builder time duringthe fabrication a case and eliminates the need for specialized equipmentand skill.

The present invention broadly comprises a valance corner including anengagement portion having first, second and third mating surfaces and asealing edge, wherein the sealing edge includes first and second sealingextensions arranged orthogonal relative to each other and having firstand second ends, respectively, each of the first, second and thirdmating surfaces are arranged orthogonal relative to the other matingsurfaces and the first and second mating surfaces form the first andsecond ends of the sealing edge, respectively. The valance cornerfurther includes a securing portion having first and second securingextensions arranged orthogonal relative to each other, the securingportion fixedly secured to the engagement portion. The first and secondsecuring extensions are arranged parallel to the first and secondsealing extensions, respectively.

The present invention also broadly comprises a valance corner consistingessentially of an engagement portion having first, second and thirdmating surfaces and a sealing edge, wherein the sealing edge includesfirst and second sealing extensions arranged orthogonal relative to eachother and having first and second ends, respectively, each of the first,second and third mating surfaces are arranged orthogonal relative to theother mating surfaces and the first and second mating surfaces form thefirst and second ends of the sealing edge, respectively. The valancecorner further consists essentially of a securing portion having firstand second extensions arranged orthogonal relative to each other, thesecuring portion fixedly secured to the engagement portion. The firstand second extensions are arranged parallel to the first and secondsealing extensions, respectively.

These and other objects and advantages of the present invention will bereadily appreciable from the following description of preferredembodiments of the invention and from the accompanying drawings andclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The nature and mode of operation of the present invention will now bemore fully described in the following detailed description of theinvention taken with the accompanying drawing figures, in which:

FIG. 1 a is a perspective view of a prior art road case in a closedarrangement; FIG. 1 b is a perspective view of the prior art road caseshown in FIG. 1 a in an open arrangement;

FIG. 1 c is an enlarged perspective view of a corner portion of theprior art road case shown in Figure la in an open arrangement;

FIG. 2 a-1 is a cross sectional view of prior art male and femalevalance extensions shown in a closed arrangement;

FIG. 2 a-2 is a cross sectional view of prior art male and femalevalance extensions shown in an open arrangement;

FIG. 2 b-1 is a top plan view of a prior art valance corner formed fromtwo valance extrusions each having a standard miter cut;

FIG. 2 b-2 is a perspective view of a prior art valance corner formedfrom two valance extrusions each having a standard miter cut;

FIG. 2 c-1 is a top plan view of a prior art valance corner formed froma single valance extrusion having a special miter cut;

FIG. 2 c-2 is a perspective view of a prior art valance corner formedfrom a single valance extrusion having a special miter cut;

FIG. 2 d-1 is a top plan view of a prior art valance corner formed froma single valance extrusion having a radius corner;

FIG. 2 d-2 is a perspective view of a prior art valance corner formedfrom a single valance extrusion having a radius corner;

FIG. 3 a is a perspective view of a road case in a closed positionincluding the present invention valance corners;

FIG. 3 b is a perspective view of the road case shown in FIG. 3 a in anopen position;

FIG. 3 c is an exploded perspective view of the road case shown in FIG.3 a;

FIG. 3 d is an exploded perspective view of the road case shown in FIG.3 a shown without panels;

FIG. 3 e is an enlarged perspective view of a corner portion of the roadcase shown in FIG. 3 a in an open arrangement

FIG. 4 a is a front perspective view of an embodiment of the presentinvention male valance corner;

FIG. 4 b is a front perspective view of an embodiment of the presentinvention female valance corner;

FIG. 5 a is a back perspective view of the embodiment of the presentinvention male valance corner shown in FIG. 4 a;

FIG. 5 b is a back perspective view of the embodiment of the presentinvention female valance corner shown in FIG. 4 b;

FIG. 6 a is a side elevational view of the embodiment of the presentinvention male valance corner shown in FIG. 4 a;

FIG. 6 b is a side elevational view of the embodiment of the presentinvention female valance corner shown in FIG. 4 b;

FIG. 7 a is another side elevational view of the embodiment of thepresent invention male valance corner shown in FIG. 4 a;

FIG. 7 b is another side elevational view of the embodiment of thepresent invention female valance corner shown in FIG. 4 b;

FIG. 8 is a bottom plan view of the embodiment of the present inventionfemale valance corner shown in FIG. 4 b;

FIG. 9 is a top plan view of the embodiment of the present inventionmale valance corner shown in FIG. 4 a;

FIG. 10 is a front exploded perspective view of an embodiment of thepresent invention male and female valance corners;

FIG. 11 a is a side elevational view of another embodiment of thepresent invention male valance corner;

FIG. 11 b is a bottom plan view of the embodiment of the presentinvention male valance corner shown in FIG. 11 a;

FIG. 12 a is a side elevational view of another embodiment of thepresent invention female valance corner; and,

FIG. 12 b is a top plan view of the embodiment of the present inventionfemale valance corner shown in FIG. 12 a.

DETAILED DESCRIPTION OF THE INVENTION

At the outset, it should be appreciated that like drawing numbers ondifferent drawing views identify identical, or functionally similar,structural elements of the invention. While the present invention isdescribed with respect to what is presently considered to be thepreferred aspects, it is to be understood that the invention as claimedis not limited to the disclosed aspects.

Furthermore, it is understood that this invention is not limited to theparticular methodology, materials and modifications described and assuch may, of course, vary. It is also understood that the terminologyused herein is for the purpose of describing particular aspects only,and is not intended to limit the scope of the present invention, whichis limited only by the appended claims.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood to one of ordinary skill inthe art to which this invention belongs. Although any methods, devicesor materials similar or equivalent to those described herein can be usedin the practice or testing of the invention, the preferred methods,devices, and materials are now described.

The present invention valance corner, e.g., valance corners 100 and 101,is used in place of a conventional brace and mitered angle cuts. Eachvalance corner includes three mating faces, i.e., mating faces 102, 104,and 106, where two faces are arranged to contact the valance extrusions,e.g., mating faces 102 and 104 contact valance extrusions 108, and theremaining face is arranged to contact an L-shaped extrusion, e.g.,mating face 106 contacts L-shaped extrusion 110, which L-shapedextrusion is orthogonally positioned relative to the valance extrusions.The two valance mating faces 102 and 104 contact each valance extrusionin a horizontal plane. The profile of the corner at these two valancefaces has the same corresponding profile for the valance, i.e., eithertongue or groove profile 112 and 114, respectively. The valance profileis translated through the valance corner to the adjoining extrusion. Inother words, the valance profile is substantially continuous from onevalance extrusion 108, through the present invention valance corner, andcontinuing on to the subsequent valance extrusion 108. The valancecorner is attached to the valance extrusion using the same mechanicalfastener as the brace, thus forming a continuous loop around theperipheral rim which provides structural strength. In addition, thevalance clamp also mechanically fastens to the intersecting protectiveangle, i.e., L-shaped extrusion, thereby providing more structuralresilience.

During the preparation of the valance components for assembly, eachvalance member, e.g., valance extrusions 108, must be cut to the properlength for the particular case. By eliminating the need to perform atime consuming miter cut on each valance extrusion member, the casefabricator saves time. The present invention valance corner requires asimple perpendicular cut made on each valance member with a standardchop saw. The cutting of the valance extrusions and L-shaped extrusionsis now performed the same way as the other protective angles used on theexterior edges of the case. The present invention valance cornerprovides a known distance from the edge of the case, e.g., length 116,to the mating face of the valance extrusion, e.g., one inch, so thatcase builders can easily and properly determine the length the valanceextrusion by merely knowing the size of the case panel.

Another advantage during the cutting stage is that several pieces ofvalance extrusion can be stacked or ganged together and cut at the sametime. Cutting the pieces at the same time makes these pieces exactly thesame length, which is ideal for manufacturing multiple cases of the samesize with the proper dimensions. Such a method saves an enormous amountof time and effort for a case fabricator.

Moreover, during assembly, the valance corner eliminates the assemblyskill required in fitting mitered valance components together. Themitered component must be fitted so that the tongue or groove forms acontinuous loop around the peripheral rim. Case fabricators must makeseveral adjustments in the positioning or to the length of the valanceextrusions to minimize any gaps at the mitered corners. A generalpractice for building many cases of the same size is to individuallymatch tongue and groove extrusions together as a pair to ensure areliable fit. This matching practice requires additional time and effortto manage the various parts through each step of the production process.The present invention valance corner eliminates this matching technique,thereby reducing storage space required between the cutting stage andthe assembly stage, and the organization effort required to keep trackof the individual pieces.

In view of the foregoing and in view of the figures, it should beappreciated that valance corners 100 and 101 each comprise engagementportion 118, which in turn comprises first, second and third matingsurfaces 102, 104 and 106, respectively, and sealing edge 120. Sealingedge 120 comprises first and second sealing extensions 122 and 124,respectively, arranged orthogonal relative to each other and comprisingfirst and second ends 126 and 128, respectively. Moreover, each of thefirst, second and third mating surfaces are arranged orthogonal relativeto the other mating surfaces and the first and second mating surfaces102 and 104, respectively, form the first and second ends 126 and 128,respectively, of the sealing edge 120. Valance corners 100 and 101further comprises securing portion 130 comprising first, second andthird securing extensions 132, 134 and 135, respectively, arrangedorthogonal relative to each other. The securing portion 130 is fixedlysecured to the engagement portion 118 using any means known in the art,e.g., welding or adhesives. Alternatively, the entire present inventionvalance corner may be formed from a single unitary material, e.g.,molded or cast metal or plastic. As can be seen in the figures, firstand second securing extensions 132 and 134, respectively, are arrangedparallel to the first and second sealing extensions 122 and 124,respectively. Third securing extension 135 is arranged to be secured toL-shaped extrusion 110. It should be appreciated that in someembodiments, securing portion 130 is arranged on an exterior surface ofengagement portion 118, or forms the exterior surface of portion 118,and that “exterior surface” is intended to mean the surface closest tothe exterior surface of the travel case. It should be furtherappreciated that the present invention valance corner permits thecutting of valance extrusions as described above in part due to theperpendicular arrangement of mating surface 102 relative to securingextension 132 and mating surface 104 relative to securing extension 134.

In some embodiments, sealing edge 120 further comprises arcuate portion136 disposed between the first and second sealing extensions 122 and124, respectively. Sealing edge 120 may further include tongue 138and/or groove 140. First and second cross sections 142 and 144 of thefirst and second mating surfaces, respectively, are preferably formed tomatch a cross section of a complimentary valance extrusion, e.g., crosssection 112 or 114. It should be appreciated that “match”, as usedherein, is intended to mean that the two cross sections are identical orsubstantially identical to each other. In other words, when assembled,the valance extrusion and present invention valance corner form acontinuous sealing edge having little or no discontinuity. Furthermore,the first and second securing extensions may each comprise a length,e.g., length 148, which is greater than a length of each of the firstand second sealing extensions, e.g., length 116.

FIGS. 11 a through 12 b depict another embodiment of the presentinvention valance corner, i.e., valance corners 200 and 201. In theseembodiments, valance corners 200 and 201 each comprise engagementportion 218, which in turn comprises first, second and third matingsurfaces 202, 204 and 206, respectively, and sealing edge 220. Sealingedge 220 comprises first and second sealing extensions 222 and 224,respectively, arranged orthogonal relative to each other and comprisingfirst and second ends 226 and 228, respectively. Moreover, each of thefirst, second and third mating surfaces are arranged orthogonal relativeto the other mating surfaces and the first and second mating surfacesform the first and second ends of the sealing edge. Valance corners 200and 201 each further comprise securing portion 230 comprising first,second and third securing extensions 232, 234 and 235, respectively,arranged orthogonal relative to each other. The securing portion isfixedly secured to the engagement portion using any means known in theart, e.g., welding or adhesives. Alternatively, the entire presentinvention valance corner may be formed from a single unitary material,e.g., molded or cast metal or plastic. As can be seen in the figures,the first and second securing extensions are arranged parallel to thefirst and second sealing extensions, respectively, while third securingextension 135 is arranged to be secured to L-shaped extrusion 110.Again, it should be appreciated that in some embodiments, securingportion 230 is arranged on an exterior surface of engagement portion218, or forms the exterior surface of portion 118, and that “exteriorsurface” is intended to mean the surface closest to the exterior surfaceof the travel case. It should be further appreciated that the presentinvention valance corner permits the cutting of valance extrusions asdescribed above in part due to the perpendicular arrangement of matingsurface 202 relative to securing extension 232 and mating surface 204relative to securing extension 234.

In these embodiments, sealing edge 220 further comprises only first andsecond sealing extensions 222 and 224, respectively, which sealingextensions are directly connected to each other, or in other words,there is no structure between the sealing extensions, such as an arcuateportion. The sealing edge may further include tongue 238 and/or groove240. As with the embodiments described supra, the cross sections of themating surfaces are formed to match the cross section of a complimentaryvalance extrusion, e.g., cross section 112 or 114. It should beappreciated that “match”, as used herein, is intended to mean that thetwo cross sections are identical or substantially identical to eachother. In other words, when assembled, the valance extrusion and presentinvention valance corner form a continuous sealing edge having little orno discontinuity.

Thus, it is seen that the objects of the present invention areefficiently obtained, although modifications and changes to theinvention should be readily apparent to those having ordinary skill inthe art, which modifications are intended to be within the spirit andscope of the invention as claimed. It also is understood that theforegoing description is illustrative of the present invention andshould not be considered as limiting. Therefore, other embodiments ofthe present invention are possible without departing from the spirit andscope of the present invention.

1. A valance corner comprising: an engagement portion comprising first,second and third mating surfaces and a sealing edge, wherein the sealingedge comprises first and second sealing extensions arranged orthogonalrelative to each other and comprising first and second ends,respectively, each of the first, second and third mating surfaces arearranged orthogonal relative to the other mating surfaces and the firstand second mating surfaces form the first and second ends of the sealingedge, respectively; and, a securing portion comprising first and secondsecuring extensions arranged orthogonal relative to each other, thesecuring portion fixedly secured to the engagement portion, wherein thefirst and second securing extensions are arranged parallel to the firstand second sealing extensions, respectively.
 2. The valance corner ofclaim 1 wherein the sealing edge further comprises an arcuate portiondisposed between the first and second sealing extensions.
 3. The valancecorner of claim 1 wherein the first sealing extension is directlyconnected to the second sealing extension.
 4. The valance corner ofclaim 1 wherein the sealing edge is a tongue.
 5. The valance corner ofclaim 1 wherein the sealing edge is a groove.
 6. The valance corner ofclaim 1 wherein first and second cross sections of the first and secondmating surfaces, respectively, match a cross section of a valanceextrusion.
 7. The valance corner of claim 1 wherein the first and secondsecuring extensions each comprise a length greater than a length of eachof the first and second sealing extensions, respectively.
 8. A valancecorner consisting essentially of: an engagement portion comprisingfirst, second and third mating surfaces and a sealing edge, wherein thesealing edge comprises first and second sealing extensions arrangedorthogonal relative to each other and comprising first and second ends,respectively, each of the first, second and third mating surfaces arearranged orthogonal relative to the other mating surfaces and the firstand second mating surfaces form the first and second ends of the sealingedge, respectively; and, a securing portion comprising first and secondextensions arranged orthogonal relative to each other, the securingportion fixedly secured to the engagement portion, wherein the first andsecond extensions are arranged parallel to the first and second sealingextensions, respectively.